Wet chemical and plasma methods of forming stable PTPD catalysts

ABSTRACT

A nano-particle comprising: an interior region comprising a mixed-metal oxide; and an exterior surface comprising a pure metal. In some embodiments, the mixed-metal oxide comprises aluminum oxide and a metallic pinning agent, such as palladium, copper, molybdenum, or cobalt. In some embodiments, the pure metal at the exterior surface is the same as the metallic pinning agent in the mixed-metal oxide in the interior region. In some embodiments, a catalytic nano-particle is bonded to the pure metal at the exterior surface. In some embodiments, the interior region and the exterior surface are formed using a plasma gun. In some embodiments, the interior region and the exterior surface are formed using a wet chemistry process. In some embodiments, the catalytic nano-particle is bonded to the pure metal using a plasma gun. In some embodiments, the catalytic nano-particle is bonded to the pure metal using a wet chemistry process.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/175,894, filed on Feb. 7, 2014, pending, which is a continuation ofU.S. patent application Ser. No. 13/033,514 filed Feb. 23, 2011, nowissued as U.S. Pat. No. 8,669,202.

FIELD OF THE INVENTION

The present invention relates to the field of catalysts. Morespecifically, the present invention relates to a method of producing acatalyst.

BACKGROUND OF THE INVENTION

Wet chemistry can be used to put small platinum particles on a ceramicsurface in order to create a catalyst. However, when the catalyst isheated up and used, the platinum particles are not sufficiently bondedto the ceramic surface. As a result, they are mobile, allowing them tomove around and find other platinum particles. Upon the platinumparticles' discovery of each other, they agglomerate into biggerplatinum particles.

For example, even if prior art processes start with ½ nanometer platinumparticles, by the time the aging test has been performed (equivalent to10 years on a car), the platinum particles have agglomerated to become16 nanometer particles.

This agglomeration of platinum particles results in a massive reductionin catalytic surface area. As a result, the performance of the catalystsignificantly decreases.

SUMMARY OF THE INVENTION

The present invention employs a pinning agent to securely bond catalyticmaterial to a core nano-particle. The pinning agent securely anchors thecatalytic material to the core nano-particle, thereby minimizing oreliminating the mobility and agglomeration of the catalytic material. Asa result, the present invention is able to provide a minimally-aging oreven a non-aging catalyst that substantially maintains the extremelysmall size of the catalytic particles on each core nano-particle,thereby maximizing the catalytic surface area.

In one aspect of the present invention, a nano-particle is comprises aninterior region and an exterior surface. The interior region comprises amixed-metal oxide, wherein the mixed-metal oxide comprises aluminumoxide and palladium. The exterior surface comprises pure metallicpalladium.

In some embodiments, the palladium in the interior region extends to andis bonded with the pure metallic palladium at the exterior surface. Insome embodiments, the nano particle comprises a diameter ofapproximately 10 nanometers or less.

In some embodiments, the mixed-metal oxide forms a center core of thenano-particle. In some embodiments, the mixed-metal oxide consists onlyof aluminum oxide and palladium.

In some embodiments, the mixed-metal oxide forms a monolayer thatsurrounds a center core of the nano-particle. In some embodiments, thecenter core comprises silica.

In another aspect of the present invention, a method of formingnano-particles comprises: loading a quantity of aluminum oxide materialand a quantity of palladium material into a plasma gun in a desiredratio; vaporizing the quantity of aluminum oxide material and thequantity of palladium material using the plasma gun, thereby forming avapor cloud comprising vaporized aluminum oxide and vaporized palladium;and quenching the vapor cloud, thereby condensing the vaporized aluminumoxide and the vaporized palladium into nano-particles. Eachnano-particle comprises an interior region and an exterior surface. Theinterior region comprises a mixed-metal oxide that includes aluminumoxide and palladium, and the exterior surface comprises pure metallicpalladium.

In some embodiments, the step of vaporizing the quantity of aluminumoxide material and the quantity of palladium material comprises: flowinga working gas into a reactor of the plasma gun; delivering energy to theworking gas, thereby forming a plasma stream; and flowing the quantityof aluminum oxide material and the quantity of palladium material intothe plasma stream.

In some embodiments, the palladium in the interior region extends to andis bonded with the pure metallic palladium at the exterior surface. Insome embodiments, the nano-particles have an average grain size ofapproximately 10 nanometers or less.

In some embodiments, the mixed-metal oxide forms a center core of thenano-particle. In some embodiments, the mixed-metal oxide consists onlyof aluminum oxide and palladium.

In yet another aspect of the present invention, a method of formingnano-particles comprises: providing a quantity of aluminum material anda quantity of palladium material in a desired ratio; and forming aplurality of nano-particles from the quantity of aluminum material andthe quantity of palladium material using a wet chemistry process. Eachformed nano-particle comprises an interior region and an exteriorsurface. The interior region comprises a mixed-metal oxide that includesaluminum oxide and palladium, and the exterior surface comprises puremetallic palladium.

In some embodiments, the aluminum material is a salt or an organiccompound, the palladium material is a salt, and the wet chemistryprocess comprises forming the mixed-metal oxide from the aluminummaterial and the palladium material via a chemical reaction. In someembodiments, the mixed-metal oxide forms a center core of eachnano-particle, and the mixed-metal oxide consists only of aluminum oxideand palladium.

In some embodiments, the step of forming the plurality of nano-particlesusing a wet chemistry process comprises forming a monolayer around acenter core of each nano-particle, the monolayer comprising themixed-metal oxide. In some embodiments, the center core of eachnano-particle comprises silica.

In some embodiments, the palladium in the interior region extends to andis bonded with the pure metallic palladium at the exterior surface. Insome embodiments, the nano-particles have an average grain size ofapproximately 10 nanometers or less.

In yet another aspect of the present invention, a catalytic carriernano-particle comprises a carrier nano-particle comprising an interiorregion and an exterior surface. The interior region comprises amixed-metal oxide that includes aluminum oxide and palladium, and theexterior surface comprises pure metallic palladium. A catalyticnano-particle is bonded to the pure metallic palladium at the exteriorsurface. The catalytic nano-particle is platinum.

In some embodiments, the palladium in the interior region extends to andis bonded with the pure metallic palladium at the exterior surface. Insome embodiments, the carrier nano-particle comprises a diameter ofapproximately 10 nanometers or less.

In some embodiments, the mixed-metal oxide forms a center core of thecarrier nano-particle. In some embodiments, the mixed-metal oxideconsists only of aluminum oxide and palladium.

In some embodiments, the mixed-metal oxide forms a monolayer thatsurrounds a center core of the carrier nano-particle. The nano-particleof claim 26, wherein the center core comprises silica.

In yet another aspect of the present invention, a method of formingnano-particles comprises: loading a quantity of aluminum oxide material,a quantity of palladium material, and a quantity of platinum materialinto a plasma gun in a desired ratio; vaporizing the quantity ofaluminum oxide material, the quantity of palladium material, and thequantity of platinum material using the plasma gun, thereby forming avapor cloud comprising vaporized aluminum oxide, vaporized palladium,and vaporized platinum; and quenching the vapor cloud, therebycondensing the vaporized aluminum oxide, the vaporized palladium, andthe vaporized platinum into carrier nano-particles. Each carriernano-particle comprises an interior region and an exterior surface. Theinterior region comprises a mixed-metal oxide that includes aluminumoxide and palladium, the exterior surface comprises a pure metallicpalladium, and a platinum nano-particle is bonded to the pure metallicpalladium at the exterior surface.

In some embodiments, the step of vaporizing the quantity of aluminumoxide material, the quantity of palladium material, and the quantity ofplatinum material comprises: flowing a working gas into a reactor of theplasma gun; delivering energy to the working gas, thereby forming aplasma stream; and flowing the quantity of aluminum oxide material, thequantity of palladium material, and the quantity of platinum materialinto the plasma stream.

In some embodiments, the palladium in the interior region extends to andis bonded with the pure metallic palladium at the exterior surface. Insome embodiments, the carrier nano-particles have an average grain sizeof approximately 10 nanometers or less.

In some embodiments, the mixed-metal oxide forms a center core of thecarrier nano-particle. In some embodiments, the mixed-metal oxideconsists only of aluminum oxide and palladium.

In yet another aspect of the present invention, a method of formingnano-particles comprises: providing a quantity of aluminum material, aquantity of palladium material, and a quantity of platinum material in adesired ratio; and forming a plurality of carrier nano-particles fromthe quantity of aluminum material, the quantity of palladium material,and the quantity of platinum material using a wet chemistry process.Each carrier nano-particle comprises an interior region and an exteriorsurface. The interior region comprises a mixed-metal oxide that includesaluminum oxide and palladium, the exterior surface comprises a puremetallic palladium, and a platinum nano-particle is bonded to the puremetallic palladium at the exterior surface.

In some embodiments, the aluminum material is a salt or an organiccompound, the palladium material is a salt, and the wet chemistryprocess comprises forming the mixed-metal oxide from the aluminummaterial and the palladium material via a chemical reaction, and forminga carrier particle suspension comprising a plurality ofaluminum-palladium carrier particles. Each aluminum-palladium carrierparticle comprises an interior region and an exterior surface. Theinterior region comprises the mixed-metal oxide that includes aluminumoxide and palladium, and the exterior surface comprises pure metallicpalladium. In some embodiments, the wet chemistry process furthercomprises mixing a platinum solution with the carrier particlesuspension, and bonding platinum nano-particles formed from the platinumsolution to the pure metallic palladium on the aluminum-palladiumcarrier particles. In some embodiments, the platinum solution is aplatinum nitrate solution or a platinum chloride solution.

In some embodiments, the aluminum material is a salt or an organiccompound, the palladium material is a salt, and the wet chemistryprocess comprises forming the mixed-metal oxide from the aluminummaterial and the palladium material via a chemical reaction, forming amonolayer of the mixed-metal oxide around a center core of each carriernano-particle, and forming a suspension of the carrier nano-particles.The center core comprises a different chemical composition from themonolayer, and each monolayer comprises an interior region and anexterior surface. The interior region comprises the mixed-metal oxidethat includes aluminum oxide and palladium, and the exterior surfacecomprises pure metallic palladium. In some embodiments, the wetchemistry process further comprises mixing a platinum solution with thesuspension of nano-particles, and bonding platinum nano-particles formedfrom the platinum solution to the pure metallic palladium on the carriernano-particles. In some embodiments, the platinum solution is a platinumnitrate solution or a platinum chloride solution. In some embodiments,the center core of each carrier nano-particle comprises silica.

In some embodiments, the palladium in the interior region extends to andis bonded with the pure metallic palladium-platinum alloy at theexterior surface. In some embodiments, the carrier nano-particles havean average grain size of approximately 10 nanometers or less.

In yet another aspect of the present invention, a method of formingnano-particles comprises: forming a plurality of aluminum-palladiumcarrier particles using a plasma gun, wherein each aluminum-palladiumcarrier particle comprises an interior region and an exterior surface,the interior region comprising a mixed-metal oxide that includesaluminum oxide and palladium, and the exterior surface comprising puremetallic palladium; and affixing a platinum nano-particle to the puremetallic palladium on each of the aluminum-palladium carrier particlesusing a wet chemistry process.

In some embodiments, forming the plurality of aluminum-palladium carrierparticles using the plasma gun comprises: loading a quantity of aluminumoxide material and a quantity of palladium material into the plasma gunin a desired ratio; vaporizing the quantity of aluminum oxide materialand the quantity of palladium material using the plasma gun, therebyforming a vapor cloud comprising vaporized aluminum oxide and vaporizedpalladium; and quenching the vapor cloud, thereby condensing thevaporized aluminum oxide and the vaporized palladium into carriernano-particles. Each carrier nano-particle comprises an interior regionand an exterior surface. The interior region comprises a mixed-metaloxide that includes aluminum oxide and palladium, and the exteriorsurface comprises pure metallic palladium.

In some embodiments, the step of vaporizing the quantity of aluminumoxide material and the quantity of palladium material comprises flowinga working gas into a reactor of the plasma gun, delivering energy to theworking gas, thereby forming a plasma stream, and flowing the quantityof aluminum oxide material and the quantity of palladium material intothe plasma stream. In some embodiments, the palladium in the interiorregion extends to and is bonded with the pure metallic palladium at theexterior surface. In some embodiments, the aluminum-palladium carrierparticles have an average grain size of approximately 10 nanometers orless.

In some embodiments, the mixed-metal oxide forms a center core of eachaluminum-palladium carrier particle. In some embodiments, themixed-metal oxide consists only of aluminum oxide and palladium.

In some embodiments, the wet chemistry process comprises mixing aplatinum solution with the aluminum-palladium carrier particles, andbonding platinum nano-particles formed from the platinum solution to thepure metallic palladium on the aluminum-palladium carrier particles. Insome embodiments, the platinum solution is a platinum nitrate solutionor a platinum chloride solution.

In some embodiments, the palladium in the interior region extends to andis bonded with the pure metallic palladium at the exterior surface. Insome embodiments, the aluminum-palladium carrier particles have anaverage grain size of approximately 10 nanometers or less.

In yet another aspect of the present invention, a catalyst comprises asupport structure, and a plurality of carrier nano-particles bonded tothe support structure. Each carrier nano-particle comprises an interiorregion and an exterior surface. The interior region comprises amixed-metal oxide, and the exterior surface comprises a pure metal. Acatalytic particle is bonded with the pure metal at the exteriorsurface.

In some embodiments, the support structure is a porous ceramic material,and the plurality of carrier nano-particles are disposed within thepores of the ceramic material. In some embodiments, the mixed-metaloxide comprises aluminum oxide and palladium. In some embodiments, thepure metal is palladium. In some embodiments, the mixed-metal oxide inthe interior region extends to and is bonded with the pure metal at theexterior surface. In some embodiments, the carrier nano-particles havean average grain size of approximately 10 nanometers or less.

In some embodiments, the mixed-metal oxide forms a center core of eachcarrier nano-particle. In some embodiments, the mixed-metal oxideconsists only of aluminum oxide and palladium.

In some embodiments, the mixed-metal oxide forms a monolayer thatsurrounds a center core of each carrier nano-particle. In someembodiments, the center core comprises silica.

In some embodiments, the exterior surface comprises a pure metal alloy.In some embodiments, the catalytic particle is platinum. In someembodiments, the catalyst is a non-aging catalyst.

In yet another aspect of the present invention, a method of forming acatalyst comprises: providing a support structure; providing a pluralityof carrier nano-particles, wherein each carrier nano-particle comprisesan interior region and an exterior surface, the interior regioncomprising a mixed-metal oxide, and the exterior surface comprising apure metal, wherein a catalytic particle is bonded with the pure metalat the exterior surface; and bonding the plurality of carriernano-particles to the support structure.

In some embodiments, the support structure is a porous ceramic material,and the plurality of carrier nano-particles are disposed within thepores of the ceramic material. In some embodiments, the mixed-metaloxide includes aluminum oxide and palladium, and the pure metalcomprises pure metallic palladium. In some embodiments, the catalyticparticle is platinum. In some embodiments, the palladium in the interiorregion extends to and is bonded with the pure metallic palladium at theexterior surface. In some embodiments, the carrier nano-particles havean average grain size of approximately 10 nanometers or less.

In some embodiments, the mixed-metal oxide forms a center core of thecarrier nano-particle. In some embodiments, the mixed-metal oxideconsists only of aluminum oxide and palladium.

In some embodiments, the step of providing a plurality of carriernano-particles comprises: loading a quantity of a first material, aquantity of a second material, and a quantity of a third material into aplasma gun in a desired ratio; vaporizing the quantity of the firstmaterial, the quantity of the second material, and the quantity of thethird material using the plasma gun, thereby forming a vapor cloudcomprising vaporized first material, vaporized second material, andvaporized third material; and quenching the vapor cloud, therebycondensing the vaporized first material, the vaporized second material,and the vaporized third material into carrier nano-particles. Eachcarrier nano-particle comprises the interior region and the exteriorsurface. In some embodiments, the step of vaporizing the quantity of thefirst material, the quantity of the second material, and the quantity ofthe third material comprises flowing a working gas into a reactor of theplasma gun, delivering energy to the working gas, thereby forming aplasma stream, and flowing the quantity of the first material, thequantity of the second material, and the quantity of the third materialinto the plasma stream.

In some embodiments, the step of providing a plurality of carriernano-particles comprises: providing a quantity of a first material, aquantity of a second material, and a quantity of third material in adesired ratio; and forming the plurality of carrier nano-particles fromthe quantity of the first material, the quantity of the second material,and the quantity of the third material using a wet chemistry process. Insome embodiments, the mixed-metal oxide comprises the first material andthe second material, the exterior surface comprises the second material,and the catalytic particle comprises the third material. In someembodiments, the wet chemistry process comprises forming the mixed-metaloxide from the first material and the second material via a chemicalreaction, and forming a carrier particle suspension comprising aplurality of carrier particles. Each carrier particle comprises theinterior region and the exterior surface, the mixed-metal oxide of theinterior region comprising the first material and the second material,and the pure metal at the exterior surface comprising the secondmaterial.

In some embodiments, the first material is an aluminum material, and thesecond material is a palladium material. In some embodiments, thealuminum material is a salt or an organic compound, and the palladiummaterial is a salt.

In some embodiments, the wet chemistry process further comprises mixinga catalytic solution with the carrier particle suspension, and bondingcatalytic nano-particles formed from the catalytic solution to the puremetal on the carrier particles. In some embodiments, the catalyticsolution is a platinum solution and the catalytic nano-particles areplatinum nano-particles. In some embodiments, the platinum solution is aplatinum nitrate solution or a platinum chloride solution.

In some embodiments, forming the mixed-metal oxide comprises forming amonolayer around a center core of each carrier particle. The center corecomprises a different chemical composition from the monolayer, and eachmonolayer comprises the interior region and the exterior surface. Insome embodiments, the mixed-metal oxide includes aluminum oxide andpalladium, and the pure metal at the exterior surface comprisespalladium. In some embodiments, the wet chemistry process furthercomprises mixing a catalytic solution with the carrier particlesuspension, and bonding catalytic nano-particles formed from thecatalytic solution to the pure metal on the carrier particles. In someembodiments, the catalytic solution is a platinum solution and thecatalytic nano-particles are platinum nano-particles. In someembodiments, the platinum solution is a platinum nitrate solution or aplatinum chloride solution. In some embodiments, the center core of eachcarrier nano-particle comprises silica.

In some embodiments, the step of providing the plurality of carriernano-particles comprises: forming a plurality of carrier particles usinga plasma gun, wherein each carrier particle comprises the interiorregion and the exterior surface; and affixing a catalytic nano-particleto the pure metal on each of the carrier particles using a wet chemistryprocess. In some embodiments, the step of forming the plurality ofcarrier particles using the plasma gun comprises: loading a quantity ofa first material and a quantity of a second material into the plasma gunin a desired ratio; vaporizing the quantity of the first material andthe quantity of the second material using the plasma gun, therebyforming a vapor cloud comprising vaporized first material and vaporizedsecond material; and quenching the vapor cloud, thereby condensing thevaporized first material and the vaporized second material into thecarrier particles. In some embodiments, the step of vaporizing thequantity of first material and the quantity of second materialcomprises: flowing a working gas into a reactor of the plasma gun;delivering energy to the working gas, thereby forming a plasma stream;and flowing the quantity of first material and the quantity of secondmaterial into the plasma stream. In some embodiments, the step ofaffixing a catalytic nano-particle to the pure metal using a wetchemistry process comprises mixing a catalytic solution with the coreparticles, and bonding catalytic nano-particles formed from thecatalytic solution to the pure metal on the carrier particles. In someembodiments, the catalytic solution is a platinum solution and thecatalytic nano-particles are platinum nano-particles. In someembodiments, the platinum solution is a platinum nitrate solution or aplatinum chloride solution. In some embodiments, bonding the pluralityof carrier nano-particles to the support structure comprises performinga calcining process.

In yet another aspect of the present invention, a nano-particlecomprises an interior region comprising a mixed-metal oxide, and anexterior surface comprising a pure metal.

In some embodiments, the mixed-metal oxide comprises aluminum oxide andpalladium. In some embodiments, the pure metal is palladium. In someembodiments, the mixed-metal oxide in the interior region extends to andis bonded with the pure metal at the exterior surface. In someembodiments, the nano-particle comprises a diameter of approximately 10nanometers or less.

In some embodiments, the mixed-metal oxide forms a center core of thenano-particle. In some embodiments, the mixed-metal oxide consists onlyof aluminum oxide and palladium.

In some embodiments, the mixed-metal oxide forms a monolayer thatsurrounds a center core of the nano-particle. In some embodiments, thecenter core comprises silica. In some embodiments, the exterior surfacecomprises a pure metal alloy. In some embodiments, the pure metal alloyis a palladium-platinum alloy.

In yet another aspect of the present invention, a method of formingnano-particles comprises providing a quantity of a first material and aquantity of a second material, and forming a plurality of nano-particlesfrom the quantity of the first material and the quantity of the secondmaterial. Each nano-particle comprises an interior region and anexterior surface. The interior region comprises a mixed-metal oxide, andthe exterior surface comprises a pure metal.

In some embodiments, the mixed-metal oxide comprises the first materialand the second material, and the pure metal comprises the secondmaterial. In some embodiments, the mixed-metal oxide comprises aluminumoxide and palladium, and the pure metal comprises palladium. In someembodiments, the mixed-metal oxide comprises aluminum oxide andpalladium, and the pure metal comprises a palladium-platinum alloy.

In some embodiments, the step of forming the plurality of nano-particlescomprises: loading the quantity of the first material and the quantityof the second material into a plasma gun in a desired ratio; vaporizingthe quantity of the first material and the quantity of the secondmaterial using the plasma gun, thereby forming a vapor cloud comprisingvaporized first material and vaporized second material; and quenchingthe vapor cloud, thereby condensing the vaporized first material and thevaporized second material into nano-particles, wherein eachnano-particle comprises the interior region and the exterior surface. Insome embodiments, the step of vaporizing the quantity of the firstmaterial and the quantity of the second material comprises: flowing aworking gas into a reactor of the plasma gun; delivering energy to theworking gas, thereby forming a plasma stream; and flowing the quantityof the first material and the quantity of the second material into theplasma stream. In some embodiments, the mixed-metal oxide comprises thefirst material and the second material, and the pure metal comprises thesecond material. In some embodiments, the first material is an aluminummaterial and the second material is a palladium material.

In some embodiments, the step of forming the plurality of nano-particlescomprises performing a wet chemistry process with the quantity of firstmaterial and the quantity of second material. In some embodiments, thewet chemistry process comprises forming the mixed-metal oxide from thefirst material and the second material via a chemical reaction. In someembodiments, the first material comprises an aluminum material, and thesecond material comprises a palladium material. In some embodiments, thealuminum material is a salt or an organic compound, and the palladiummaterial is a salt. In some embodiments, the mixed-metal oxide forms acenter core of each nano-particle, and the mixed-metal oxide consistsonly of aluminum oxide and palladium. In some embodiments, the wetchemistry process comprises forming a monolayer around a center core ofeach nano-particle. The monolayer comprises the mixed-metal oxide. Insome embodiments, the center core of each nano-particle comprisessilica.

In some embodiments, the mixed-metal oxide in the interior regionextends to and is bonded with the pure metal at the exterior surface. Insome embodiments, the nano-particles have an average grain size ofapproximately 10 nanometers or less.

In yet another aspect of the present invention, a nano-particlecomprises an interior region comprising a mixed-metal oxide, an exteriorsurface comprising a pure metal, and a catalytic particle affixed to thepure metal. The catalytic particle has a chemical composition differentfrom the pure metal and the mixed-metal oxide.

In some embodiments, the mixed-metal oxide comprises a first materialand a second material, the pure metal comprises the second material, andthe catalytic particle comprises a third material. In some embodiments,the mixed-metal oxide forms a monolayer that surrounds a center core ofthe nano-particle. In some embodiments, the center core comprisessilica.

In some embodiments, the mixed-metal oxide comprises aluminum-oxide anda metallic pinning agent that does not comprise platinum, the pure metalcomprises the metallic pinning agent, and the catalytic particlecomprises platinum. In some embodiments, the metallic pinning agentcomprises copper, molybdenum, or cobalt. In some embodiments, thecatalytic particle comprises a metal alloy. In some embodiments, themetal alloy is a palladium-platinum alloy. In some embodiments, themetallic pinning agent comprises copper, molybdenum, or cobalt, and thecatalytic particle comprises a palladium-platinum alloy.

In some embodiments, the mixed-metal oxide in the interior regionextends to and is bonded with the pure metal at the exterior surface. Insome embodiments, the nano particle comprises a diameter ofapproximately 10 nanometers or less.

In some embodiments, the catalytic particle is a nano-particle. In someembodiments, the catalytic particle comprises a diameter ofapproximately 1 nanometer or less. In some embodiments, the catalyticparticle comprises a diameter of approximately ½ nanometer.

In yet another aspect of the present invention, a method of forming anano-particle comprising: providing a carrier nano-particle, wherein thecarrier nano-particle comprises an interior region and an exteriorsurface, the interior region comprising a mixed-metal oxide, and theexterior surface comprising a pure metal; and affixing a catalyticparticle to the pure metal, wherein the catalytic particle has achemical composition different from the pure metal and the mixed-metaloxide.

In some embodiments, the mixed-metal oxide is formed from a firstmaterial and a second material, the pure metal is formed from the secondmaterial, and the catalytic particle is formed from a third material. Insome embodiments, the mixed-metal oxide forms a monolayer that surroundsa center core of the carrier nano-particle. In some embodiments, thecenter core comprises silica.

In some embodiments, the mixed-metal oxide comprises aluminum-oxide anda metallic pinning agent that does not comprise platinum, the pure metalcomprises the metallic pinning agent, and the catalytic particlecomprises platinum. In some embodiments, the metallic pinning agentcomprises copper, molybdenum, or cobalt. In some embodiments, thecatalytic particle comprises a metal alloy. In some embodiments, themetal alloy is a palladium-platinum alloy. In some embodiments, themetallic pinning agent comprises copper, molybdenum, or cobalt, and thecatalytic particle comprises a palladium-platinum alloy.

In some embodiments, the mixed-metal oxide in the interior regionextends to and is bonded with the pure metal at the exterior surface. Insome embodiments, the carrier nano-particle comprises a diameter ofapproximately 10 nanometers or less.

In some embodiments, the catalytic particle is a nano-particle. In someembodiments, the catalytic particle comprises a diameter ofapproximately 1 nanometer or less. In some embodiments, the catalyticparticle comprises a diameter of approximately ½ nanometer.

In some embodiments, the steps of providing the carrier nano-particleand affixing the catalytic particle to the pure metal are performedusing a plasma gun. In some embodiments, the steps of providing thecarrier nano-particle and affixing the catalytic particle to the puremetal are performed using a wet chemistry process.

In some embodiments, providing the carrier nano-particle comprisesloading a quantity of a first material and a quantity of a secondmaterial into a plasma gun in a desired ratio, vaporizing the quantityof the first material and the quantity of the second material, therebyforming a vapor cloud comprising vaporized first material and vaporizedsecond material, and quenching the vapor cloud, thereby condensing thevaporized first material and the vaporized second material into thecarrier nano-particle. The carrier nano-particle comprises the interiorregion and the exterior surface. In some embodiments, the step ofvaporizing the quantity of the first material material and the quantityof the second material comprises flowing a working gas into a reactor ofthe plasma gun, delivering energy to the working gas, thereby forming aplasma stream, and flowing the quantity of the first material and thequantity of the second material into the plasma stream. In someembodiments, the step of affixing the catalytic particle to the puremetal is performed using a wet chemistry process. In some embodiments,the wet chemistry process comprises mixing a catalytic solution with thecarrier nano-particle, and bonding a catalytic particle formed from thecatalytic solution to the pure metal on the carrier nano-particle. Insome embodiments, the catalytic solution is a platinum solution and thecatalytic particle is a platinum nano-particle. In some embodiments, theplatinum solution is a platinum nitrate solution or a platinum chloridesolution.

In yet another aspect of the present invention, a method of formingcatalytic nano-particles comprises: providing a plurality of carriernano-particles, wherein each carrier nano-particle comprises an interiorregion and an exterior surface, the interior region comprising amixed-metal oxide, and the exterior surface comprising a pure metal; andaffixing a catalytic nano-particle to the pure metal on each carriernano-particle.

In some embodiments, the step of affixing the catalytic nano-particle tothe pure metal is performed using a plasma gun. In some embodiments, thestep of affixing the catalytic nano-particle to the pure metalcomprises: loading the plurality of nano-particles and a quantity ofcatalytic material into a plasma gun in a desired ratio, vaporizing thequantity of catalytic material, thereby forming a vapor cloud comprisingvaporized catalytic material, and quenching the vapor cloud, therebycondensing the vaporized catalytic material into catalyticnano-particles that are bonded to the pure metal on the carriernano-particles.

In some embodiments, the plurality of carrier nano-particles has anaverage grain size of approximately 10 nanometers or less. In someembodiments, each catalytic nano particle comprises a diameter ofapproximately 1 nanometer or less. In some embodiments, each catalyticnano-particle comprises a diameter of approximately ½ nanometer.

In some embodiments, the step of affixing the catalytic nano-particle tothe pure metal is performed using a wet chemistry process. In someembodiments, the step of affixing a catalytic nano-particle to the puremetal using a wet chemistry process comprises mixing a catalyticsolution with the plurality of carrier nano-particles, and bondingcatalytic nano-particles formed from the catalytic solution to the puremetal on the plurality of carrier nano-particles. In some embodiments,the catalytic solution is a platinum solution and the catalyticnano-particles are platinum nano-particles. In some embodiments, theplatinum solution is a platinum nitrate solution or a platinum chloridesolution.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a cross-sectional view of one embodiment of catalyticnano-particles bonded with a carrier nano-particle in accordance withthe principles of the present invention.

FIG. 2 illustrates a cross-sectional view of another embodiment ofcatalytic nano-particles bonded with a carrier nano-particle inaccordance with the principles of the present invention.

FIG. 3A illustrates a cross-sectional view of one embodiment of acatalyst in accordance with the principles of the present invention.

FIG. 3B illustrates a cross-sectional view of another embodiment of acatalyst in accordance with the principles of the present invention.

FIG. 4 illustrates one embodiment of a method of producing catalyticcarrier nano-particles and a catalyst therefrom in accordance with theprinciples of the present invention.

FIG. 5 illustrates one embodiment of a method of producing catalyticcarrier nano-particles using a plasma gun in accordance with theprinciples of the present invention.

FIG. 6 illustrates another embodiment of a method of producing catalyticcarrier nano-particles using a plasma gun in accordance with theprinciples of the present invention.

FIG. 7 illustrates one embodiment of a plasma-based particle productionsystem in accordance with the principles of the present invention.

FIG. 8 illustrates another embodiment of a plasma based particleproduction system in accordance with the principles of the presentinvention.

FIG. 9 illustrates one embodiment of a method of catalytic carriernano-particles using a wet chemistry process in accordance with theprinciples of the present invention.

FIG. 10 illustrates one embodiment of a method of producing catalyticcarrier nano-particles using both a plasma gun and a wet chemistryprocess in accordance with the principles of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following description is presented to enable one of ordinary skillin the art to make and use the invention and is provided in the contextof a patent application and its requirements. Various modifications tothe described embodiments will be readily apparent to those skilled inthe art and the generic principles herein may be applied to otherembodiments. Thus, the present invention is not intended to be limitedto the embodiment shown but is to be accorded the widest scopeconsistent with the principles and features described herein.

This disclosure provides several embodiments of the present invention.It is contemplated that any features from any embodiment can be combinedwith any features from any other embodiment. In this fashion, hybridconfigurations of the illustrated and describer embodiments are wellwithin the scope of the present invention.

This disclosure refers to both particles and powders. These two termsare equivalent, except for the caveat that a singular “powder” refers toa collection of particles. The present invention may apply to a widevariety of powders and particles. Powders that fall within the scope ofthe present invention may include, but are not limited to, any of thefollowing: (a) nano-structured powders (nano-powders), having an averagegrain size less than 250 nanometers and an aspect ratio between one andone million; (b) submicron powders, having an average grain size lessthan 1 micron and an aspect ratio between one and one million; (c)ultra-fine powders, having an average grain size less than 100 micronsand an aspect ratio between one and one million; and (d) fine powders,having an average grain size less than 500 microns and an aspect ratiobetween one and one million.

Various aspects of the disclosure may be described through the use offlowcharts. Often, a single instance of an aspect of the presentdisclosure may be shown. As is appreciated by those of ordinary skill inthe art, however, the protocols, processes, and procedures describedherein may be repeated continuously or as often as necessary to satisfythe needs described herein. Additionally, it is contemplated thatcertain method steps of the invention can be performed in alternativesequences to those disclosed in the flowcharts. Accordingly, the scopeof the claims should not be limited to any specific order of methodsteps unless the order is explicitly required by the language of theclaims.

FIG. 1 illustrates a cross-sectional view of one embodiment of catalyticnano-particles 130 bonded with a carrier nano-particle 100 in accordancewith the principles of the present invention. The carrier nano-particle100 comprises an interior region and an exterior surface 115. Theexterior surface 115 defines the perimeter of the carrier nano-particle100. In some embodiments, the carrier nano-particle 100 comprises adiameter of approximately 10 nanometers or less, which has been found tobe an ideal size. Although, it is contemplated that other diameters arewithin the scope of the present invention.

The interior region is the region between the center of the carrierparticle and the exterior surface 115. This interior region comprises amixed-metal oxide 110. In some embodiments, the mixed-metal oxide 110comprises aluminum oxide along with an accompanying metal. In someembodiments, this accompanying metal is palladium. Other accompanyingmetals that have been found to be suitable are copper, molybdenum, andcobalt. It is contemplated that other oxides and other metals may beused as well.

The exterior surface comprises one or more pure metal regions 120consisting of pure metal. Metals that have been found to be suitable forthese pure metal regions include palladium, copper, molybdenum, andcobalt. However, it is contemplated that other metals may be used aswell. For the purposes of this disclosure, the terms “pure metal” and“pure metallic” should be interpreted to mean that the regions consistonly of metal and are characterized by the absence of any other type ofmaterial. For example, the pure metal regions 120 may comprise a metalor a metal-metal alloy, but they may not comprise any ceramic material.The purpose of these purely metal regions 120 is to provide exposedregions at the exterior surface 115 of the carrier nano-particle 100 towhich catalytic nano-particles 130 will have a strong attraction.

The catalytic nano-particles 130 are bonded, or otherwise affixed, tothese pure metal regions 120. In some embodiments, these catalyticnano-particles 130 comprise or consist of platinum. In some embodiments,these catalytic nano-particles 130 comprise or consist of a platinumalloy, such as a platinum-palladium alloy. However, it is contemplatedthat other catalytic materials may be used as well. In some embodiments,the catalytic nano-particles 130 have an average grain size ofapproximately 1 nanometer or less. In some embodiments, the catalyticnano-particles 130 have an average grain size of approximately ½nanometer. However, it is contemplated that other sizes are within thescope of the present invention. Although FIG. 1 shows more than one puremetal region 120 on the carrier nano-particle 110 and more than onecatalytic nano-particle 130 bonded to the carrier nano particle 110, itis contemplated that other quantities of these elements are within thescope of the present invention. For example, in some embodiments, thecarrier nano-particle 110 comprises only one distinct pure metal region120 and one distinct catalytic nano-particle 130 bonded to the carriernano-particle 110. In some embodiments, the carrier nano-particle 110comprises more than one distinct pure metal region 120 and more than onedistinct catalytic nano-particle 130 bonded to the carrier nano-particle110.

The pure metal regions 120 are bonded to the mixed-metal oxide 110 andact as pinning agents to securely affix the catalytic nano-particles 130to the carrier nano-particle 100, thereby reducing or eliminating themobility of the catalytic nano-particles 130 and preventing theiragglomeration.

FIG. 2 illustrates a cross-sectional view of one embodiment of catalyticnano-particles 230 bonded with a carrier nano-particle 200 in accordancewith the principles of the present invention. The carrier nano-particle200 comprises an interior region and an exterior surface 215. Theexterior surface 215 defines the perimeter of the carrier nano-particle200. In some embodiments, the carrier nano-particle 200 comprises adiameter of approximately 10 nanometers or less, which has been found tobe an ideal size. Although, it is contemplated that other diameters arewithin the scope of the present invention.

The interior region is the region between the center of the carrierparticle and the exterior surface 215. This interior region comprises amixed-metal oxide 210. In some embodiments, the mixed-metal oxide 210comprises aluminum oxide along with an accompanying metal. In someembodiments, this accompanying metal is palladium. Other accompanyingmetals that have been found to be suitable are copper, molybdenum, andcobalt. It is contemplated that other oxides and other metals may beused as well.

The embodiment of FIG. 2 is very similar to the embodiment of FIG. 1.However, in contrast to the interior region of carrier nano-particle100, which is shown in FIG. 1 as comprising only the mixed-metal oxide110 from its center to its exterior surface 115 and pure metal regions120, the interior region of carrier nano-particle 200 is shown in FIG. 2as having a center core 205 around which a monolayer of the mixed-metaloxide 210 is formed. In some embodiments, this center core 205 is formedfrom a ceramic material. In some embodiments, this center core 205 isformed from silica. However, it is contemplated that a other materialsmay be suitable to form the center core 205.

Similar to the exterior surface of carrier nano-particle 100, theexterior surface of carrier nano-particle 200 comprises one or more puremetal regions 220 consisting of pure metal. Metals that have been foundto be suitable for these pure metal regions include palladium, copper,molybdenum, and cobalt. However, it is contemplated that other metalsmay be used as well. For the purposes of this disclosure, the terms“pure metal” and “pure metallic” should be interpreted to mean that theregions consist only of metal and are characterized by the absence ofany other type of material. For example, the pure metal regions 220 maycomprise a metal or a metal-metal alloy, but they may not comprise anyceramic material. The purpose of these purely metal regions 220 is toprovide exposed regions at the exterior surface 215 of the carriernano-particle 200 to which catalytic nano-particles 230 will have astrong attraction.

As discussed above with respect to the embodiment of FIG. 1, thecatalytic nano-particles 230 are bonded, or otherwise affixed, to thesepure metal regions 220. In some embodiments, these catalyticnano-particles 230 comprise or consist of platinum. In some embodiments,these catalytic nano-particles 230 comprise or consist of a platinumalloy, such as a platinum-palladium alloy. However, it is contemplatedthat other catalytic materials may be used as well. In some embodiments,the catalytic nano-particles 230 have an average grain size ofapproximately 1 nanometer or less. In some embodiments, the catalyticnano-particles 230 have an average grain size of approximately ½nanometer. However, it is contemplated that other sizes are within thescope of the present invention. Although FIG. 2 shows more than one puremetal region 220 on the carrier nano-particle 210 and more than onecatalytic nano-particle 230 bonded to the carrier nano-particle 210, itis contemplated that other quantities of these elements are within thescope of the present invention. For example, in some embodiments, thecarrier nano-particle 210 comprises only one distinct pure metal region220 and one distinct catalytic nano-particle 230 bonded to the carriernano-particle 210. In some embodiments, the carrier nano-particle 210comprises more than one distinct pure metal region 220 and more than onedistinct catalytic nano-particle 230 bonded to the carrier nano-particle210.

As previously discussed with respect to the embodiment of FIG. 1, thepure metal regions 220 are bonded to the mixed-metal oxide 210 and actas pinning agents to securely affix the catalytic nano-particles 230 tothe carrier nano-particle 200, thereby reducing or eliminating themobility of the catalytic nano-particles 230 and preventing theiragglomeration.

Whether it is with respect to the embodiments of FIGS. 1-2 or some otherembodiment within the scope of the present invention, the chemical andstructural compositions of the elements can vary. For example, in someembodiments, the mixed-metal oxide comprises or consists of aluminumoxide, the pure metal regions comprise or consist of palladium, and thecatalytic particles comprise or consist of platinum. In someembodiments, the interior region consists only of the mixed-metal oxide.In some embodiments, the interior region comprises a ceramic center coresurrounded by a monolayer of mixed-metal oxide. In some embodiments, thepure metal comprises or consists of a metal other than palladium, suchas copper, molybdenum, or cobalt. In some embodiments, the catalyticparticles comprise or consist of a palladium-platinum alloy. In someembodiments, the pure metal comprises or consists of a metal other thanpalladium, such as copper, molybdenum, or cobalt, and the catalyticparticles comprise or consist of a palladium-platinum alloy.

Whether it is with respect to the embodiments of FIGS. 1-2 or some otherembodiment within the scope of the present invention, the bonding of oneor more of the catalytic nano-particles with the carrier nano-particledefines the formation of catalytic carrier nano-particles. Thesecatalytic carrier nano-particles can be impregnated or otherwise affixedonto a catalyst support in order to form a usable catalyst. In someembodiments, the catalyst support is a ceramic material. In someembodiments, the catalyst support is an oxide material. In someembodiments, the catalyst support is a monolith. In some embodiments,the catalyst support is an extrudate. Such supports have found utilitydue to their highly accessible and large surface area, as high as 250m²/g. In some embodiments, the catalyst support is a macroscopic supportparticle. In such an embodiment, the size of the macroscopic supportparticle is selected to provide maximum surface area to which thecatalytic carrier nano-particles are bonded or fixed. In someembodiments, the catalyst support is a porous structure.

In some embodiments, the mixed-metal oxide 210 can be anything between apartial monolayer and multiple monolayers. In some embodiments, puremetal regions 220 can be anything between a metal atom partially bondedto oxygen atoms in the matrix, with at least one bonding site to anchora metal particle, and a metal atom cluster with one or more atomsincorporated in the mixed-metal oxide and one or more pure metal atomsavailable to alloy with a metallic catalysis particle (e.g., a platinumnano-particle).

FIG. 3A illustrates a cross-sectional view of one embodiment of acatalyst 300A in accordance with the principles of the presentinvention. The catalyst 300A comprises a catalyst support 310A, which isa porous structure, impregnated with catalytic carrier nano-particles330A, such as the catalytic carrier nano-particles discussed above. As aporous structure, the catalyst support 310A comprises a plurality ofpores 320. A close up view of the impregnated porous support 310A isillustrated in FIG. 3A, showing catalytic carrier nano-particles 330Afixed within the pores 320.

FIG. 3B illustrates a cross-sectional view of another embodiment of acatalyst 300B in accordance with the principles of the presentinvention. The catalyst 300B comprises a catalyst support 310B, which isa macro support, impregnated with catalytic carrier nano-particles 330B,such as the catalytic carrier nano-particles discussed above.

It is contemplated that a variety of different methods can be employedto impregnate the catalyst supports 310A, 310B with the catalyst carriernano particles 330A, 330B. In some embodiments, a liquid dispersion ofthe catalyst carrier nano-particles is applied to the catalyst support.The catalyst support is allowed to dry and/or a drying process isperformed on the catalyst support. As the liquid in the dispersionevaporates, the catalyst carrier nano-particles settle onto the surfaceof the support and/or into the pores within the support. When theimpregnated catalyst support dries, electrostatic interactions and otherforces between the catalyst carrier nano-particles and the catalystsupport effectuate some adhesion. Advantageously, such forces cause thenano-particles to stick onto the surfaces and pores of the support.

In some embodiments, a calcining step is performed to form oxide-oxidebonds between the nano-particles and the catalyst support, exposing themto heat, pressure, or a combination thereof. The calcining temperatureis generally from 350 to 1000 degrees centigrade, and the pressure is onthe order of ambient atmosphere to several atmospheres. For optimumoxide-oxide bonds, a portion of the catalytic carrier nano-particles ischosen to correspond to the material of which the catalyst support iscomprised. By way of example, if a portion of the catalyst carriernano-particles comprises alumina, then the catalyst support preferablycomprises alumina, although dissimilar oxides are also contemplated. Dueto the physical and chemical bond between the catalyst support and thenano-particles, islands of nano-particles that are bonded, fixed orotherwise pinned to the surfaces of the catalyst support will notmigrate and coalesce during catalytic conversion. The surface area forcatalysis remains high, and therefore the catalytic activity remainshigh. In effect, operations such as fine chemical plants and oilrefineries will not be required to stop operations and swap outineffective catalyst supports with fresh catalyst supports with the samefrequency as existing processes, thereby increasing throughput at theplants and refineries and reducing their overall cost of operation.

FIG. 4 illustrates one embodiment of a method of producing catalyticcarrier nano-particles and a catalyst therefrom in accordance with theprinciples of the present invention.

At step 410, a plurality of carrier nano-particles is formed. Eachcarrier nano-particle comprises an interior region and an exteriorsurface. The interior region comprises a mixed-metal oxide, while theexterior surface comprises a pure metal. The carrier nano-particles cancomprise any of the elements discussed above with respect to FIGS. 1-2.

At step 420, at least one catalytic particle is bonded to each of thecarrier nano-particles, thereby forming catalytic carriernano-particles. The catalytic particle is bonded to the pure metal atthe exterior surface of the carrier particle. The catalytic particle cancomprise any of the elements discussed above with respect to FIGS. 1-2.

At step 430, the plurality of carrier nano-particles are bonded to asupport structure. One example of such a support structure is a porousceramic material. However, it is contemplated that other types ofsupport structures can be employed. The support structure can compriseany of the elements discussed above with respect to FIGS. 3A-B.

FIG. 5 illustrates one embodiment of a method of producing catalyticcarrier nano-particles using a plasma gun in accordance with theprinciples of the present invention.

At step 510, a first material, a second material, and a third materialare loaded into a plasma gun in a desired ratio. In some embodiments,the first material is an aluminum oxide material, the second material isa palladium material, and the third material is a platinum material.However, it is contemplated that other materials can be used in additionor as an alternative to these materials.

At step 520, the first material, the second material, and the thirdmaterial are vaporized using the plasma gun, thereby forming a vaporcloud that comprises vaporized first material, vaporized secondmaterial, and vaporized third material.

At step 530, the vapor cloud is quenched, thereby condensing thevaporized material into carrier nano-particles with catalyticnano-material bonded to the carrier nano-particles. Each nano-particlecomprises an interior region and an exterior surface. The interiorregion comprises a mixed-metal oxide. The exterior surface comprises apure metal. The catalytic nano-material is bonded to the pure metal atthe exterior surface.

It is contemplated that the present invention can employ a variety ofdifferent types of plasma gun systems to vaporize and quench the loadedmaterial into nano-particles. In a preferred embodiment, thenano-particles are substantially uniform in size. The nano-particles canbe formed by introducing micron-sized material into a plasma process,such as described and claimed in the co-owned and co-pending applicationSer. No. 11/110,341, filed Apr. 19, 2005, and titled “High ThroughputDiscovery of Materials Through Vapor Phase Synthesis,” and the co-ownedand co-pending application Ser. No. 12/151,935, filed May 8, 2008, andtitled “Highly Turbulent Quench Chamber,” both of which are herebyincorporated by reference as if set forth herein.

FIG. 7 illustrates one embodiment of a plasma-based particle productionsystem 700 that can be used in accordance with the principles of thepresent invention. System 700 uses a plasma process and a highlyturbulent quench chamber 745 to produce nano-particles. The system 700comprises a precursor supply device 710 and a working gas supply device720 fluidly coupled to a plasma production and reaction chamber 730. Anenergy delivery system 725 is also coupled with the plasma productionand reactor chamber 730. The plasma production and reactor chamber 730includes an injection port 740 that communicates fluidly with theconstricting quench chamber 745. One or more ports 790 can also allowfluid communication between the quench chamber 745 and a controlledatmosphere system 770. The quench chamber 745 is also fluidly coupled toan outlet 765.

Generally, the chamber 730 operates as a reactor, producing an outputcomprising particles within a gas stream. Production includes the basicsteps of combination, reaction, and conditioning as described laterherein. The system combines precursor material supplied from theprecursor supply device 710 and working gas supplied from the workinggas supply device 720 within the energy delivery zone of the chamber730.

In some embodiments, the precursor material comprises a powderedsubstance. In some embodiments, the precursor material is micron-sized.In some embodiments, the precursor material comprises an average graindiameter of 500-600 nanometers. In some embodiments, the precursormaterial comprises an average grain diameter of one micrometer. In someembodiments, the precursor material comprises an average grain diametergreater than or equal to 5 microns.

The system energizes the working gas in the chamber 730 using energyfrom the energy supply system 725, thereby forming a plasma. The plasmais applied to the precursor material within the chamber 730 to form anenergized, reactive mixture. This mixture comprises one or morematerials in at least one of a plurality of phases, which may includevapor, gas, and plasma. The reactive mixture flows from the plasmaproduction and reactor chamber 730 into the quench chamber 745 throughan injection port 740.

The quench chamber 745 preferably comprises a substantially cylindricalsurface 750, a frusto-conical surface 755, and an annular surface 760connecting the injection port 740 with the cylindrical surface 750. Thefrusto-conical surface 760 narrows to meet the outlet 765. The plasmaproduction and reactor chamber 730 includes an extended portion at theend of which the injection port 740 is disposed. This extended portionshortens the distance between the injection port 740 and the outlet 765,reducing the volume of region in which the reactive mixture and theconditioning fluid will mix, referred to as the quench region. In apreferred embodiment, the injection port 740 is arranged coaxially withthe outlet 765. The center of the injection port is positioned a firstdistance d₁ from the outlet 765. The perimeter of the injection port ispositioned a second distance d₂ from a portion of the frusto-conicalsurface 755. The injection port 740 and the frusto-conical surface 755form the aforementioned quench region therebetween. The space betweenthe perimeter of the injection port 740 and the frusto-conical surface755 forms a gap therebetween that acts as a channel for supplyingconditioning fluid into the quench region. The frusto-conical surface755 acts as a funneling surface, channeling fluid through the gap andinto the quench region.

While the reactive mixture flows into the quench chamber 745, the ports790 supply conditioning fluid into the quench chamber 745. Theconditioning fluid then moves along the frusto-conical surface 755,through the gap between the injection port 740 and the frusto-conicalsurface 755, and into the quench region. In some embodiments, thecontrolled atmosphere system 770 is configured to control the volumeflow rate or mass flow rate of the conditioning fluid supplied to thequench region.

As the reactive mixture moves out of the injection port 740, it expandsand mixes with the conditioning fluid. Preferably, the angle at whichthe conditioning fluid is supplied produces a high degree of turbulenceand promotes mixing with the reactive mixture. This turbulence candepend on many parameters. In a preferred embodiment, one or more ofthese parameters is adjustable to control the level of turbulence. Thesefactors include the flow rates of the conditioning fluid, thetemperature of the frusto-conical surface 755, the angle of thefrusto-conical surface 755 (which affects the angle at which theconditioning fluid is supplied into the quench region), and the size ofthe quench region. For example, the relative positioning of thefrusto-conical surface 755 and the injection port 740 is adjustable,which can be used to adjust the volume of quench region. Theseadjustments can be made in a variety of different ways, using a varietyof different mechanisms, including, but not limited to, automated meansand manual means.

During a brief period immediately after entering the quench chamber 745,particle formation occurs. The degree to which the particles agglomeratedepends on the rate of cooling. The cooling rate depends on theturbulence of the flow within the quench region. Preferably, the systemis adjusted to form a highly turbulent flow, and to form very dispersedparticles. For example, in preferred embodiments, the turbidity of theflow within the quench region is such that the flow has a ReynoldsNumber of at least 1000.

Still referring to FIG. 7, the structure of the quench chamber 745 ispreferably formed of relatively thin walled components capable ofdissipating substantial quantities of heat. For example, the thin-walledcomponents can conduct heat from inside the chamber and radiate the heatto the ambient.

Substantial heat is emitted, mostly in the form of radiation, from thereactive mixture following its entry into the quench chamber 745. Thequench chamber 745 is designed to dissipate this heat efficiently. Thesurfaces of the quench chamber 745 are preferably exposed to a coolingsystem (not shown). In a preferred embodiment, the cooling system isconfigured to control a temperature of the frusto-conical surface 755.

Following injection into the quench region, cooling, and particleformation, the mixture flows from the quench chamber 745 through theoutlet port 765. Suction generated by a generator 795 moves the mixtureand conditioning fluid from the quench region into the conduit 792. Fromthe outlet port 765, the mixture flows along the conduit 792, toward thesuction generator 795. Preferably, the particles are removed from themixture by a collection or sampling system (not shown) prior toencountering the suction generator 795.

Still referring to FIG. 7, the controlled atmosphere system 770 isfluidly coupled to a chamber 785, which is fluidly coupled to the quenchregion through port(s) 790, into which conditioning fluid is introducedfrom a reservoir of the controlled atmosphere system 770 through aconduit 780. As described above, the conditioning fluid preferablycomprises argon. However, other inert, relatively heavy gases areequally preferred. Also, as discussed above, the preferable mechanism ofproviding the conditioning fluid into the quench chamber 745 is theformation of a pressure differential between the quench chamber 745 andthe outlet 765. Such pressure differential will draw the conditioningfluid into the quench chamber 745 through the ports 790. Other methodsof providing the conditioning fluid include, but are not limited to,forming positive pressure within the chamber 785.

The angle of the frusto-conical surface affects the angle at which theconditioning fluid is supplied into the quench region, which can affectthe level of turbulence in the quench region. The conditioning fluidpreferably flows into the quench region along a plurality of momentumvectors. The greater the degree of the angle between the momentumvectors, the higher the level of turbulence that will be produced. In apreferred embodiment, the high turbulent quench chamber comprises afrusto-conical surface that is configured to funnel at least twoconditioning fluid momentum vectors into the quench region such thatthere is at least a 90 degree angle between the two momentum vectors. Itis contemplated that other angle degree thresholds may be applied aswell. For example, attention may also be paid to the angle formedbetween at least one of the conditioning fluid momentum vectors and themomentum vector of the reactive mixture. In one embodiment of a highlyturbulent quench chamber, a reactive mixture inlet is configured tosupply the reactive mixture into the quench region along a firstmomentum vector, the frusto-conical surface is configured to supply theconditioning fluid to the quench region along a second momentum vector,and the second momentum vector has an oblique angle greater than 20degrees relative to the first momentum vector.

The size of the quench region also affects the level of turbulence inthe quench region. The smaller the quench region, the higher the levelof turbulence that will be produced. The size of the quench region canbe reduced by reducing the distance between the center of the injectionport 740 and the outlet 765.

The high turbulence produced by the embodiments of the present inventiondecreases the period during which particles formed can agglomerate withone another, thereby producing particles of more uniform size, and insome instances, producing smaller-sized particles. Both of thesefeatures lead to particles with increased dispersibility and increasedratio of surface area to volume. While the plasma process describedabove is extremely advantageous in producing the nano-particles, it iscontemplated that the nano-particles can be produced in other ways aswell.

FIG. 6 illustrates another embodiment of a method of producing catalyticcarrier nano-particles using a plasma gun in accordance with theprinciples of the present invention.

At step 610, a first material and a second material are loaded into aplasma gun in a desired ratio. In some embodiments, the first materialis an aluminum oxide material and the second material is a palladiummaterial. However, it is contemplated that other materials can be usedin addition or as an alternative to these materials.

At step 620, the first material and the second material are vaporizedusing the plasma gun, thereby forming a vapor cloud that comprisesvaporized first material and vaporized second material.

At step 630, the vapor cloud is quenched, thereby condensing thevaporized first material and vaporized second material into carriernano-particles. Each carrier nano-particle comprises an interior regionand an exterior surface. The interior region comprises a mixed-metaloxide. The exterior surface comprises a pure metal.

At step 640, the carrier nano-particles and a third material are loadedinto a plasma gun in a desired ratio. In some embodiments, the thirdmaterial is a platinum material. However, it is contemplated that othermaterials can be used in addition or as an alternative to a platinummaterial.

At step 650, the third material is vaporized using the plasma gun,thereby forming a vapor cloud that comprises vaporized third material.

At step 660, the carrier nano-particles are mixed with the vaporizedthird material in the vapor cloud.

At step 670, the vapor cloud is quenched, thereby condensing thevaporized third material into catalytic nano-particles and bonding themto the pure metal at the exterior surface of the carrier nano-particles.

As discussed above, it is contemplated that the present invention canemploy a variety of different types of plasma gun systems to vaporizeand quench the loaded material into nano-particles. The nano-particlescan be formed by introducing micron-sized material into a plasmaprocess, such as described and claimed in the co-owned and co-pendingapplication Ser. No. 12/152,111, filed May 9, 2008, and titled “PowderCoating System and Method Including Gun Extension,” which is herebyincorporated by reference as if set forth herein.

FIG. 8 illustrates another embodiment of a plasma based particleproduction system 800 in accordance with the principles of the presentinvention. System 800 comprises a plasma production chamber 820, acoating chamber 830, a cooling conduit 870, a sampling system 880, and amotive pump 890. The plasma production chamber 820 and coating chamber830 are preferably enclosed in a motive gas supply chamber 810.

The motive gas supply chamber 810 is fluidly coupled to a motive gassupply system 815, which is configured to supply a motive gas.Preferably, the motive gas is an inert gas, such as argon. Furthermore,the chamber 810 preferably include airtight inlets and outletsconfigured to permit conduits to pass through to supply the plasmaproduction chamber 820 and coating chamber 830. The motive gas supplychamber 810 can include airtight couplings that permit these conduits topass through while preventing leakage either into or out of thechambers. Furthermore, output from the coating chamber 830 can flow intothe cooling conduit 870, which can also passes through a wall of themotive gas supply chamber 810. Preferably, the cooling conduit 870 alsoexits the motive gas supply chamber through an airtight coupling.

The plasma production chamber 820 preferably includes several types ofinputs for receiving power, gas, and target materials. Inputs areprovided to the chamber 820 by a variety of supply systems through meansdescribed below. Functional aspects of these supply systems are alsodescribed below.

Various input conduits fluidly couple the plasma gas supply mixer 840with a first gas supply vessel 842 and a second gas supply vessel 844.The plasma gas supply system 840 includes an outlet fluidly coupled withan inlet of the plasma production chamber 820. The gas supply system 840and the production chamber 820 are coupled by a conduit that passesthrough the motive gas supply chamber 810. Preferably, but not shown inthe figure, an overall system controller provides control signals to theplasma gas supply system 840.

The power supply system 825 is also coupled to the plasma productionchamber 820 through conduits that pass through the motive gas supplychamber 810. Preferably, but not shown in the figure, an overall systemcontroller provides control signals to the power supply system 825.

The coater supply system 852 houses precursor material and includes anexternally controllable delivery system fluidly coupled to a materialsinlet of the plasma production chamber 820. The supply system 852 iscoupled with the production chamber 820 by a conduit that passes throughthe motive gas supply chamber 810. Preferably, but not shown in thefigure, an overall system controller provides control signals to thesupply system 852.

Preferably, the conduits that run between the plasma gas supply system840 and the production chamber 820, the coater supply system 852 and theplasma production chamber 820, and the power supply system 825 and theplasma production chamber 820, all enter the motive gas supply chamber810 through air-tight seals. In some embodiments, the conduits of thevarious supply systems all have dedicated airtight entrances to themotive gas supply chamber 810. In some embodiments, a single airtightentrance accommodates multiple conduits.

The coating chamber 830 preferably includes inlets for motive gas,coater material-plasma mixture, and coatee material, as well as anoutlet to provide an output to the cooling conduit 870. The inlets formotive gas couple the motive gas supply chamber 810 to the interior ofthe coating chamber 830. Preferably, these inlets are channels ofadjustable size that directly coupled the two chambers, yet permit forcontrolled flow from the supply chamber 810 into the coating chamber830.

Coatee material is stored within the coatee material supply system 854,which preferably sits outside the motive gas supply chamber 810. Aconduit passes from the supply system 854 through the motive gas supplychamber 810 and also through a wall of the coating chamber 830. Thecoatee material supply system 854 includes a controllable deliverysystem that provides coatee material to the conduit. Preferably, theconduit enters both chambers though airtight seals. The conduitterminates within the coating chamber at a selected location.Preferably, the location of the terminus is selected based on parametersof operation. Also preferably, but not shown, an overall systemcontroller is configured to supply control signals to the supply system854.

The cooling conduit 870 connects the coating chamber 830 with thesampling system 880. The conduit 870 exits the motive gas supply chamber810 through airtight means. The cooling conduit 870 includes a firstsection 872, a second section 874, third section 876, and fourth section878. The sections are joined by gas input couplings that contain gasinput features. The first section 872 is joined to the second section874 by the gas input coupling 862. In turn, the second section 874 isjoined to the third section 876 by the gas input coupling 864. The gasinput coupling 866 joins the third section 876 to the fourth section878.

In the illustrated embodiment, no gas is shown being supplied to the gasinput couplings 862, 864, 866 for input into the cooling conduit 870.However, gas can be supplied through one or more of the gas inputcouplings.

The sampling system 880 is fluidly coupled between the cooling conduit870 and the motive pump 890. The sampling system 880 is configured toreceive output from the cooling conduit 870, sample material havingappropriate characteristics from the output, and permit remains of theoutput to flow to the motive pump 890, which is fluidly coupled througha conduit to the sampling system 880.

During operation, the supply systems 840, 852, and 825 provide plasmagas, coater material, and power, respectively, to the plasma productionchamber 820. Power from the delivery system 825 is used to energize gasfrom the supply system 840 to produce a plasma within the productionchamber 820. The coater material supply system 852 provides coatermaterial in metered amounts into the plasma production chamber 820,exposing the coater material to plasma formed therein.

The overall control system (not shown) sends signals to the plasma gassupply system 840, coater material supply system 852, and power supplysystem 825 to set operational parameters. The plasma gas supply system840 determines the ratio of mixing for the first and second gasses toproduce plasma gas, as well as the rate at which the plasma gas feedsinto the plasma production chamber 820. In a preferred embodiment, thefirst gas is hydrogen and the second gas is an inert gas, such as argon.The coater material supply system 852 determines the rate at which thecoater material is supplied into the plasma production chamber 820. Thepower supply system 825 determines the voltage and amperage at whichpower is supplied to the plasma production chamber. In combination,these parameters determine the characteristics of the plasma producedwithin the plasma production chamber 820, as well as the characteristicsof the plasma-coatee material mixture also produced within the chamber820. Furthermore, although the coater supply system is described asproviding only a single coater material into the plasma productionchamber 820 at a single location, in some embodiments of the presentinvention, the coater supply system 852 supplies a plurality ofmaterials into the plasma production chamber 820 at one or morelocations.

The motive gas supply chamber 810 receives motive gas, typically aninert gas such as argon, from a preferably dedicated motive gas supplysystem 815. The motive gas supply chamber 810 provides an airtightenclosure around the plasma production chamber 820 and coating chamber830. The motive gas supply system 815 preferably maintains a pressurewithin the motive gas supply chamber 810 that slightly exceeds theambient pressure of the environment in which the system 800 is housed,regardless of any variation in suction force generated by the motivepump 890.

The coating chamber 830 receives a coater material and plasma mixturefrom the plasma production chamber 820. The coating chamber 830 alsoreceives motive gas through input features. Preferably, these inputfeatures provide for an adjustable flow rate of motive gas into thecoating chamber 830. Motive gas flow is preferably motivated by themotive pump 890 by pulling a negative pressure on the conduit 870,motivating mass flow through the outlet of the coating chamber 870.However, the flow rate of the motive gas into the coating chamber 830 ispreferably controlled by the overall control system.

Furthermore, the coatee material supply system 854 provides a meteredstream of coater material through the coatee material conduit to theconduit's terminus location within the coating chamber 830. The rate atwhich coatee material is provided into the chamber 830 preferably isdetermined by the overall control system. Furthermore, although theterminus of the coatee material supply conduit is shown to depositmaterial only at one location within the coating chamber 830, in someembodiments of the present invention, the terminus deposits coateematerial at a plurality of locations within the conduit (e.g., in anannular configuration surrounding output of the plasma productionchamber 820).

Preferably, coating chamber 830 is shaped and the operational parametersof the apparatus 800 are controlled so that the coater material andplasma mixture enters the coating chamber and reaches a maximum enthalpyshortly thereafter. Most preferably, this maximum of enthalpy occurswithin a defined region of the coating chamber 830, with the averageenthalpy of the mixture falling as it moves away from that region withits minimum (within the coating chamber 830) coming at the outlet to thecooling conduit 870. For example, as illustrated in FIG. 8, the maximumenthalpy occurs in region 1. In these embodiments, the location of theterminus for delivery of the coatee material is chosen to be outside themaximum region and between the maximum region and the outlet.

Furthermore, in certain embodiments of the present invention, thecoating chamber 830 is shaped and the operational parameters of theapparatus 800 are chosen so that the coater material begins to condensefrom the coater material and gas mixture within a defined region of thecoating chamber 830. For example, in FIG. 8, the region 2 is such aninitial condensation region. Typically, the initial condensation regionlies between the maximum enthalpy region and the outlet of the coatingchamber 830. In some embodiments, the coatee material is delivered intothe initial condensation region. Preferably in these embodiments,sufficient enthalpy remains in the condensing mixture to vaporize thecoatee material. Thus, as the coater material is condensing to formparticles, the coatee material is vaporized mixed with the condensingparticles. As the coater material gas particle mixture mixes with thevaporized coatee material and moves towards the outlet, the coatercondenses on the coatee particles, forming a plurality of coatedparticles.

The cooling conduit 870 receives the coated particle and gas mixturefrom the coating chamber 830. Preferably, the mixture is pulled into thecooling conduit by the motive pump 890. However, in some embodiments, amotive pump or other system within the sampling system 880 provides somemotive force to pull the mixture. Of course, to some extent, pressureprovided by the plasma production chamber 820 and the motive gas supply815 motivate the movement of the mixture into the cooling conduit 870.

In some embodiments, the cooling conduit 870 is equipped with an activecooling system. In some embodiments, a gas is supplied into the gasinput couplings 862, 864, or 866. In some of these embodiments, the gasis a cooling and entraining gas. In some of these embodiments, the gasis a passivating gas configured to reduce the reactivity of thecondensed particles within the mixture.

As mentioned above, the sampling system 880 preferably permits themotive pump 890 to provide a motive force therethrough. However, in someembodiments the sampling system 880 provides additional motive force. Insome embodiments the sampling system 880 supplants the motive forceprovided by the motive pump 890 and provides a substitute motive forceto the cooling conduit 870.

It is contemplated that the sampling system 880 can be configured in avariety of ways. In one embodiment, the sampling system 880 comprises asampling structure, at least one filled aperture formed in the samplingstructure, and at least one unfilled aperture formed in the samplingstructure. Each filled aperture is configured to collect particles fromthe mixture stream, such as by using a filter. The sampling structure isconfigured to be adjusted between a pass-through configuration and acollection configuration. The pass-through configuration comprises anunfilled aperture being fluidly aligned with a conduit, such as conduit870, thereby allowing the unfilled aperture to receive the mixturestream from the conduit and the mixture stream to flow through thesampling structure without substantially altering the particle contentof the mixture stream. The collection configuration comprises a filledaperture being fluidly aligned with the conduit, thereby allowing thefilled aperture to receive the mixture stream and collect particleswhile the mixture stream is being flown through the filled aperture. Itis contemplated that the sampling structure can be adjusted between thepass-through configuration and the collection configuration in a varietyof ways. In one embodiment, the sampling structure is a disk-shapedstructure including an annular array of apertures, wherein the annulararray comprises a plurality of the filled apertures and a plurality ofthe unfilled apertures. The sampling structure is rotatably mounted to abase, wherein rotational movement of the sampling structure results inthe adjustment of the sampling structure between the pass-throughconfiguration and the collection configuration. In another embodiment,the sampling structure is a rectangular-shaped structure including alinear array of apertures, wherein the linear array comprises aplurality of the filled apertures and a plurality of the unfilledapertures. The sampling structure is slideably mounted to a base,wherein sliding of the sampling structure results in the adjustment ofthe sampling structure between the pass-through configuration and thecollection configuration.

It is contemplated that the particles of the present invention can beformed and bonded using wet chemistry methods in addition or as analternative to the use of a plasma-based system. Such methods include,but are not limited to, the methods described in the followingreferences, which are hereby incorporated by reference as if set forthherein: Adschiri et al., “Hydrothermal synthesis of metal oxidenanoparticles at supercritical conditions” (Journal of NanoparticleResearch 3: 227-235, 2001); Kratohvil et al., “Preparation andproperties of coated, uniform, inorganic colloidal particles: I.Aluminum (hydrous) oxide on hematile, chromia, and titania” (AdvancedCeramics Materials 2:4, 1987); Matijevic, “Monodispersed Metal (Hydrous)Oxides—A Fascinating Field of Colloid Science” (Acc. Chem. Res. 14,22-29, 1981); Lakshmi et al., “Sol-Gel Template Synthesis ofSemiconductor Oxide Micro- and Nanostructures” (Chem. Mater. 9,2544-2550, 1997); Carnes et al., “Synthesis, Characterization, andAdsorption Studies of Nanocrystalline Aluminum Oxide and a BiometallicNanocrystalline Aluminum Oxide/Magnesium Oxide” (Chem. Mater. 14,2922-2929, 2002); Zhu et al., “γ-Alumina Nanofibers Prepared fromAluminum Hydrate with Poly(ethylene oxide) Surfactant” (Chem. Mater. 14,2086-2093, 2002); Alexander et al., “PROCESS FOR MODIFYING THEPROPERTIES OF A SILICA SOL AND PRODUCT THEREOF” (U.S. Pat. No.2,892,797, Issued Jun. 30, 1959); Alexander et al., “AQUASOLS OFPOSITIVELY-CHARGED COATED SILICA PARTICLES AND THEIR PRODUCTION” (U.S.Pat. No. 3,007,878, Issued Nov. 7, 1961); Moore, Jr., “STABLE POSITIVELYCHARGED ALUMINA COATED SILICA SOLS AND THEIR PREPARATION BYPOST-NEUTRALIZATION” (U.S. Pat. No. 3,719,607, Issued Mar. 6, 1973);Moore, Jr., “STABLE POSITIVELY CHARGED ALUMINA COATED SILICA SOLS” (U.S.Pat. No. 3,745,126, Issued Jul. 10, 1973); and Kovarik, “METAL OXIDESOLS” (U.S. Pat. No. 3,864,142, Issued Feb. 4, 1975).

FIG. 9 illustrates one embodiment of a method 900 of catalytic carriernano-particles using a wet chemistry process in accordance with theprinciples of the present invention.

At step 910, a first material and a second material are provided in adesired ratio. In some embodiments, the first material is an aluminummaterial and the second material is a palladium material. In someembodiments, the aluminum material is a salt or an organic compound, andthe palladium material is a salt. However, it is contemplated that othermaterials can be used in addition or as an alternative to thesematerials.

At step 920, a plurality of carrier nano-particles are formed from thefirst material and the second material via a chemical reaction using awet chemistry process. Each carrier nano-particle comprises an interiorregion and an exterior surface, the interior region comprises amixed-metal oxide. The exterior surface comprises a pure metal. In someembodiments, the center core of each carrier nano-particle comprisessilica.

At step 930, a suspension of the carrier nano-particles is formed andmixed with a catalytic solution (a solution comprising particles havingcatalytic properties). In some embodiments, the catalytic solution is aplatinum solution. In some embodiments, the platinum solution is aplatinum nitrate solution or a platinum chloride solution. However, itis contemplated that other types of catalytic solutions can be used.

At step 940, the catalytic solution reacts with the carriernano-particles, thereby pinning catalytic nano-particles to the puremetal at the exterior surface of the carrier nano-particles. Forexample, in one embodiment, platinum ions from the catalytic solutionreact with the oxide surface of the carrier nano-particles, resulting indiscreet platinum atoms ending up on the surface of the carriernano-particles. These atoms can diffuse over the oxide surface andagglomerate with other platinum atoms to form platinum nano-particles.When a platinum nano-particle reaches a palladium atom cluster bonded inthe oxide surface, the platinum cluster alloys with the palladiumcluster, thereby pinning the platinum cluster. In some embodiments, thecarrier nano-particles have an average grain size of approximately 10nanometers or less. In some embodiments, the catalytic nano-particleshave an average grain size of approximately 1 nanometer or less. In someembodiments, the catalytic nano-particles have an average grain size ofapproximately ½ nanometer. However, it is contemplated that other sizesare within the scope of the present invention.

FIG. 10 illustrates one embodiment of a method 1000 of producingcatalytic carrier nano-particles using both a plasma gun and a wetchemistry process in accordance with the principles of the presentinvention.

At step 1010, a first material and a second material are loaded into aplasma gun in a desired ratio. In some embodiments, the first materialis an aluminum oxide material and the second material is a palladiummaterial. However, it is contemplated that other materials can be usedin addition or as an alternative to these materials.

At step 1020, the first material and the second material are vaporizedusing the plasma gun, thereby forming a vapor cloud that comprisesvaporized first material and vaporized second material.

At step 1030, the vapor cloud is quenched, thereby condensing thevaporized first material and vaporized second material into carriernano-particles. Each carrier nano-particle comprises an interior regionand an exterior surface. The interior region comprises a mixed-metaloxide. The exterior surface comprises a pure metal. One objective of thepresent invention is to mix an easily oxidizable and reducible metalinto a carrier oxide (e.g., aluminum oxide, ceria, zirconia, silica,etc.). The idea is that the metal (e.g., Pd, Cu, Zn, Cr, Ni, etc.) getsincorporated into the oxide matrix. However, by making this an oxygendeficient environment, such as by adding H₂ into the carrier gas, someof the metal is in its non-oxidized state on the surface of theparticle. One method that can be used is to form mixed-metal oxidenano-particles, and then expose them to a reducing environment, such asH₂ at temperature or a H₂ plasma, and partially reduce the metal-oxideon the surface. The carrier-oxide would not easily reduce in thisenvironment. However, the oxidation state of the metal buried below thesurface of the mixed metal oxide is not crucial. The result is amixed-metal oxide particle with metal atoms on the surface that are notfully oxidized. These metal atoms form the anchor for the metalliccatalysis particles added later, such as described in steps 930 and 940of FIG. 9 and steps 1040 and 1050 of FIG. 10.

At step 1040, the carrier nano-particles are mixed with a catalyticsolution. In some embodiments, the catalytic solution is a platinumsolution. In some embodiments, the platinum solution is a platinumnitrate solution or a platinum chloride solution. However, it iscontemplated that other types of catalytic solutions can be used.

At step 1050, the catalytic solution reacts with the carriernano-particles, thereby pinning catalytic nano-particles to the puremetal at the exterior surface of the carrier nano-particles. Forexample, in one embodiment, platinum ions from the catalytic solutionreact with the oxide surface of the carrier nano-particles, resulting indiscreet platinum atoms ending up on the surface of the carriernano-particles. These atoms can diffuse over the oxide surface andagglomerate with other platinum atoms to form platinum nano-particles.When a platinum nano-particle reaches a palladium atom cluster bonded inthe oxide surface, the platinum cluster alloys with the palladiumcluster, thereby pinning the platinum cluster. In some embodiments, thecarrier nano-particles have an average grain size of approximately 10nanometers or less. In some embodiments, the catalytic nano-particleshave an average grain size of approximately 1 nanometer or less. In someembodiments, the catalytic nano-particles have an average grain size ofapproximately ½ nanometer. However, it is contemplated that other sizesare within the scope of the present invention.

The present invention has been described in terms of specificembodiments incorporating details to facilitate the understanding ofprinciples of construction and operation of the invention. Suchreference herein to specific embodiments and details thereof is notintended to limit the scope of the claims appended hereto. It will bereadily apparent to one skilled in the art that other variousmodifications may be made in the embodiment chosen for illustrationwithout departing from the spirit and scope of the invention as definedby the claims.

What is claimed is:
 1. A method of forming nano-particles, the methodcomprising: forming a plurality of aluminum-palladium carriernano-particles using a plasma gun, wherein the aluminum-palladiumcarrier nano-particles comprise an interior region and an exteriorsurface, the interior region comprising a mixed-metal oxide thatincludes aluminum oxide and palladium, and the exterior surfacecomprising pure metallic palladium; and affixing platinum nano-particlesto the pure metallic palladium on the aluminum-palladium carriernano-particles using a wet chemistry process; wherein forming theplurality of aluminum-palladium carrier nano-particles using the plasmagun comprises: loading a quantity of aluminum oxide material and aquantity of palladium material into the plasma gun in a desired ratio,wherein the aluminum oxide material and the palladium material are inpowder form; vaporizing the quantity of aluminum oxide material and thequantity of palladium material using the plasma gun, thereby forming avapor cloud comprising vaporized aluminum oxide and vaporized palladium;and quenching the vapor cloud, thereby condensing the vaporized aluminumoxide and the vaporized palladium into carrier nano-particles.
 2. Themethod of claim 1, wherein the step of vaporizing the quantity ofaluminum oxide material and the quantity of palladium materialcomprises: flowing a working gas into a reactor of the plasma gun;delivering energy to the working gas, thereby forming a plasma stream;and flowing the quantity of aluminum oxide material and the quantity ofpalladium material into the plasma stream.
 3. The method of claim 2,wherein the working gas comprises argon and H₂.
 4. The method of claim2, wherein the palladium in the interior region extends to and is bondedwith the pure metallic palladium at the exterior surface.
 5. The methodof claim 1, wherein the palladium in the interior region extends to andis bonded with the pure metallic palladium at the exterior surface. 6.The method of claim 1, wherein the aluminum-palladium carriernano-particles have an average grain size of 10 nanometers or less. 7.The method of claim 1, wherein the platinum nano-particles have adiameter of 1 nanometer or less.
 8. The method of claim 1, wherein theplatinum nano-particles have a diameter of approximately 0.5 nanometer.9. The method of claim 1, wherein the mixed-metal oxide forms a centercore of the aluminum-palladium carrier nano-particles.
 10. The method ofclaim 9, wherein the mixed-metal oxide consists only of aluminum oxideand palladium.
 11. The method of claim 1, wherein the wet chemistryprocess comprises: mixing a platinum solution with thealuminum-palladium carrier nano-particles; and bonding platinumnano-particles formed from the platinum solution to the pure metallicpalladium on the aluminum-palladium carrier nano-particles.
 12. Themethod of claim 11, wherein the platinum solution is a platinum nitratesolution or a platinum chloride solution.
 13. A method of forming acatalyst, the method comprising: providing a support structure; forminga plurality of aluminum-palladium nano-particles using a plasma gun; andbonding the plurality of nano-particles to the support structure;wherein forming the plurality of aluminum-palladium carriernano-particles using the plasma gun comprises: loading a quantity ofaluminum oxide material and a quantity of palladium material into theplasma gun in a desired ratio, wherein the aluminum oxide material andthe palladium material are in powder form; vaporizing the quantity ofaluminum oxide material and the quantity of palladium material using theplasma gun, thereby forming a vapor cloud comprising vaporized aluminumoxide and vaporized palladium; and quenching the vapor cloud, therebycondensing the vaporized aluminum oxide and the vaporized palladium intocarrier nano-particles.
 14. The method of claim 13, wherein: the supportstructure is a porous ceramic material; and the nano-particles aredisposed within the pores of the ceramic material.
 15. The method ofclaim 13, wherein the aluminum-palladium carrier nano-particles have anaverage grain size of 10 nanometers or less.
 16. The method of claim 13,wherein the platinum nano-particles have a diameter of 1 nanometer orless.
 17. The method of claim 13, wherein the platinum nano-particleshave a diameter of approximately 0.5 nanometer.